Dry powder cement paint preparation



106. "COMPOSH'IONS, i i

which serves as a binder an veh c e or land cement, a combination of inert filler material's an a suflicient quantity of caseins, or a mixture of caseins to effectively neutralfie the free alkali present in the cement; second, a re-action-mixture designed to retard the initial sgt ting and agcelerate the ultim' ate Hardening of the cement" 'emp oye y'tf'tisftmm, a i le forming mixture consisting of caseins or mix ure 0 case s oge er with the necessary auxilia materials for producing an adhesive colloidal gel e pain Another object o vefit'id'filh the provision of a dry powder cement paint preparation in which a l o dy or base, a r e;a ction-mixture, and a vehicle forming mixture are blended into each other in the prop'erproportions and ground to a suitable degree of fineness, the material being marketed as 9. gr powder but which must be mixed with 'water e ore app ication to a surfacef'" A further object of the invention is the provision of a cement paint which will readily mix with water and have the characteristics of a slightly heavy oil paint in that the cement paint will flow and spread and have high flattening properties almost identical with those of oil paints, the paint being readily applied by means of a brush or spray to give a uniform coating.

Another object of the invention is the provision of a cement paint having the characteristics of a slightly heavy oil paint but which will form an integral bond in the outer surface of the wall so that it is possible to apply the paint to any surface to which a non -elastic coating is desired, such surfaces being preferably cementitious, the paint .-being effectively neutral and having the property of locking in lime other alkalies present in the suffacefthereby permitting further application of lacquers, enamels, oil paints, without danger gf saponification of the oil vehicle of the finished "amend its consequent raking down.

9 1 COATING 0R PLASTIC. i Patented 0a. 23, 1934 1,973 141 1,978,141

DRY POWDER CEMENT PAINT PREPARATION William P. D. Moross, Chattanooga, Team, as-

signor to American Cement Paint 00., Ross ville, 6a., a corporation of Georgia No Drawing. Application June 19, 1930,

Serial No. 462,430

2 Claims. (Cl. 134-46) This invention relates to a dry powder cement tion and these elements include a bgdy or base, a paint preparation. re-action-mixture and a vehicle {grmin mixture An object of the invention is the provision of a "and each of these various mixtures or elements dry powder paint which consists of three essential will be described in detail. "i= 5 elements. First, a body or base composed of l-"ort- For thebggy of the paint or 1 a u. t and lic Portland cement and n: or Portland cement and any single inert iral fille; material having proper covering and hi ng properties, and with which the cement will, in proper proportions, set and harden to a hard and durable stonelike mass, may be used with a reasonable degree of satisfaction. and E Fla: or olin in small percentages add somew a 0 case 0 spread and may be used advantageously, either singly or in combination. The particular choice of mineral 'fillei' fnaterials employed is in nowise essential to the basic principles involved, as long as the materials used satisfy the requirements mentioned above. Where are used for colored paints, these also are inert materials and may properly be classed with inert mineral filler.

The proportions of cement to inert filler are not meanness principlesi'nvolved. There are, of course, optimum proportions which are to be preferred. For maximum durability of the paint film, the proportions of cement to total inert filler should be such that these materials alone will set and harden to a hard and durable stone-like mass. If no inert filler at all were used, the coating would be hard and durable, but would have some tendency to crack, owing to the contraction of the cement on setting. If so great a proportion of inert filler is used that the cement crystals cannot properly interlock, the coating will of course not have the maximum degree of durability.

The actual limits of the proportions which may be used to best advantage will depend upon the specific gravity and consequent bulk of the inert filler. For such fillers as amo hous silica, whiting and others of mar'Ffille smfic'fty, as much as Inmmt by weight inert filler may be used with sixty percent cemem've a coating of satisfactory hardness and durability,

while as little as to ninety 100 percent cement I give reasonable freedom from cracking. For other filler materials these limits will of course vary.

It is to be specifically understood that the above limits represent merely the optimum pro- 5 ins and. i is therefore possible, because of this 110 vehicle, to use less cement noted above and still preparation the reacting materials must be dry have a reasonably satisfactory paint. For maxipowders, the alkalir ig earth metal oxides, hymum durability, however, the proportions lying d roxides and hydrous oxidesand carbonates are between the limits cited above are most advanespecially applicable. Moreover, if a lum is 6 tageous and are preferred. reacted with an alkaline-earth-metal oxi dafi- It will be appreciated that the paint must be mixed with water before application to the surface and in view of this it is necessary to regulate the setting speed of the cement. For this purpose a suitable retardingggent is employed to stay the setting oi the cement for several hours. Such a retarding agent as cal i sulphate in suitable proportion is preferred. This agent may be introduced as ground dry sum or calcium sulphate in the Portland cement or it may be introduced as a re-action Eroguet formed by two or more materi s. er re en nay be employed either singly or in combination with the calcium sulphate and such agents may include other alkaline-earth metal sul hates such as barium or strontium. re era y, owever, thgcaLiuw lLhafe emgpyed as a re- W action 1- I be ' e irvdrous a ummum oxre can quantities up to approximately twenty percent by weight of the cement in the body. Any percentage from about one percent up to twenty percent will have an appreciable and beneficial effect. If used in quantities greater than approximately twenty percent, the hydrous aluminum oxide will decrease the ultimate strength of the cement.

It has been found thoroughly satisfactory to produce both the hydrous aluminum oxide and the alkaline-earth-metal sulphate in the same carbonate as mentioned above amounts of the reacting materials employed entirely upon the quantity of alkaline-earth-metal sulphate produced. This in turn, for optimum results, is of course based upon the quantity of cement present in the body.

It is to be understood that it is not essential to the principles of this invention that both the hydrous aluminum oxide and the alkaline-earthmetal sulphate be produced in the same reaction rather than in two separate reactions. Producing the two materials by means of the same reaction is a refinement and simplification and is, of course, to be preferred.

To summarize, the reaction mixture consists of (a) a soluble sulphate or mixture ofsoluble sulphates'ftoge ther with an alkaline earth-metal compound or a mixture of a1kalirie-arth metal compounds, which will in water react together to produce an alkaline-eartfi -metal sulphate or a mixture of alliallne afth-nietal sulphates, and b) a soluble aluminum salt or a mixture of soluble aliiminum saltsftogether with an alkalinehe quantity of retarding agent used, and consequently the qualities of reacting materials employed to produce the retarding agent, will depend upon the quantity of cement used in the body, due allowance being made for the retarding agent already present in the cement. cium sul hate for example, in quantities f I I I 2, 1'8 this s e =1 ac e era e re-acting materials should Be'in' such proportions tothFE n'i'nt that a suitable retarding action is obtained. Normally, Portland cement contains slightly less than two percent calcium sulphate, while as much as three percent may be used with a retarding effect. In the present paint a somewhat greater percentage than this can be used and a retarding effect still obtained, owing to the tendency of a caseinate vehicl to absorb lime and so serve as a contributory reta lden Or, because of this retarding efiect of the caseinate vehicle, a reasonably satisfactory paint may be produced without introducing any other retarder. For optimum results, however, a small percentage of calcium sulphate as the retarder is preferred, the same being introduced as a reaction product. Portland cement ordinarily requires some twenty-eight days to acquire its full strength. This rate of hardening will give a reasonably satisfactory paint. It is obvious, however, that a paint film which will gain its full strength more rapidly is to be preferred. It has been found that aluminum h droxide, or, more correctly h drous aluminum oxide precipitated in the cemen in a fiigmy Eyd'r'ous condition as a reaction product, tends to accelerate the rate of hardening of the coating. Whether this hydrous aluminum oxide reacts with lime resent in the mixture to form one or more of the ca Tc'i'um 'a'lummates, or whether it joins the arm minum oxide, is not definitely known. In view of the small quantity of free lime present in the present paint, however, and 0 other reactions involving the lime, the latter behaviour is thought {We most probable. l This drous I compoun or this reaction and aluminum sulphate as the aluminum compound. Inasmuch as c a bonate may also be used as the inert mineral filler 1n the body, its use in the reaction mixture is a refinement and simplification and is therefore advantageous.

1 consists essenor a mixture of nt A hardemn agent may be a os 5 age to render the vehicle water-resistant after drying and a reserv tive ent may be introduced to protect Ehe dry caseins in the paint from bacterial deed terioration.

The casein goes into solution as a colloidal dro izes in wa er to an acid, it may be reacted with a carbonate. SmcN'dry-powder paint dried will not redissolve.

roxide h dro .EZH'e'nngarEonaE, Hiesame reagiomgfill m-an aline-earth-metal urn o e.

earth-metal compound or a mixture of alkalinelkali-caseinate el, which reacts with a hardenin a ent to produce an insoluble gel which when i I06. COMPOSITIONS,

COATING OR PLASTIC.

( For the solvent or paw agent there is a i wide rangeo c oice a r sw ch ybe odi raw-MW um S111- i mwnr-nrm 1 e soium na e, or a comma 1 or more of fiese materials may be used. Or, more generally still, any alkaline chemical comund which will in wat'eflpzflrogize to yield an alkali, or any combination 0 suc compounds, or any two or more chemical compounds, which will in water react together to produce an alkali or a mixture of alkalies, may be used with varying degrees of satisfaction.

In general the milder alkalies are to be preferred especially mildly alkaline salts since the stronger alkalies cause a reaction w ch is diflicult to con ro and greater care must be exercised in percentages used. It is also essential since the paint is sold in dry form that less hygroscofiic salts are desirable.

e alkali asg ate gel produced will have varying properties depending both upon the kind and quantity of solvent employed. The casein, after going into colloidal solution, starts breaking down into its primary cleavage products. After this breaking down has proceeded to a certain point, the gel ceases to be adhesive and also becomes practically inert chamically. The length of time during which the gel remains adhesive and chemically active may properly be called the "working lifef of the gel as it is in the case of those gels which are used as gl u e s. With some of the stronger alkalies, if used in substantial quantities, the'ge"l will have a working life of only an hour or two. With some of the milder alkalies the gel may have a working life of twentyfouf ho'urs or more. When lime or some of the other iarlkaline-earth-mgtgl hydroxides are used as the so ven e wor ing life may e a ort period as from ten to fifteen minutes, owing to the rapid formation of an insoluble alkaline-earth-metal caseinate. It is wor y o no e, owever, a a combination of lime or other alkaline-earth; metal hydroxide and some alkali-group (sodium, 5;, -otassium orammonium) alka ine sa can e used to produce a gel which will have a working life of several hours. An alkaline-earth-metal hydroxide can be used both as the solven and hardener. Since casein will go into so u ion colloi'dally in any aqueous solution whichissufllciently alkaline (above the iso-electric point of casein, pH 4.6), it probably gives the initial product an unsaturated calcium caseinate or other alkalineeart -meta caseina e. is caseinate then reacts further with the ii rue or other alkalineearth-metal compound to produce the insoluble alkaline-earth-caseinate. This latter reactiofi 'is largely one of physical adsorption on the part of the caseinate gel and the more nearly saturated 7;,- this gel becomes, the more highly water-resistant it will be after drying. A gel so produced, however, has a short working life.

When an ammonia alum is used in the reaction-mixturmh an alkaline-earthmetal oxide or hydroxide, ammonia era {WW tex 5 and is available as a solvent or cutting agent for the casein used in the vehicl 'forin'ing mixture. If such a reaction-mixture is used in suitable proportions, it will not be necessary to use any other solvent agent for the casein. This is a refinement possessing certain advantages. The ammonia and casein react together to produce an The calcium or ammonium-caseinate el. other aIEalme-earEH-metal lans present then displaces the ammonia, forming with the casein an 5 alkal ipe earth;metal case'mate. The ammonia,

being volatile, a 'orate s p g as the pain s. The removal of ihe 5mm agent through evaporation gives a vehicle appreciably more waterresistant after drying than can be obtained with a solvent agent which remains in the paint. 0n

the other hand, because of the high alkalineearth-metal content of the mixture necessary for this reaction, We, the gel does not have a very long working life, and is preferred in special paints adapted to restricted uses, where it would be quite advantageous. The viscosity of the alkali-caseinate el will depend both upon the E5? vent and the quantity of the solvent or solvents used. with any given solvent or mixture of solvents, increasing the quantity of solvent, increases the viscosity of the resulting gel, up to a certain poirltT'an'd'beyond this point increasing the quantity of solvent or solvents decreases the viscosity again. The viscosity will also vary slightly, though 10 5 not materially, with the 0L casein or caseins used. Where the alkali-locking'br neutralizing capacity of the caseinate vehicle is not considered of importance it is of course advantageous to use both the kind and quantity of solvent which will give the maximum viscosity, since this makes it possible tous'e'asmaller amount of casein to give a finished paint of a given viscosity. Since casein is one of the most costly materials used in the manufacture of cement paints, this is commercially desirable. v

iagrax is preferable as the solvent a ent, for ",5"

t e reason that in the proper quantities it gives F,

a gel having thoroughly satisfactory properties and in addition, borax is an excellent preservative 16 agent for dry casein. M

For the nin a ent or insolubilizer any x of a number oi materIals may m. 'Para 51- ormaldeh de, aldehyde-ammonia, hexarneth enetetr WIFE 3r me other fofialdeh de-condmoduct which will 11 water Emmi yield formaldehyde may be used. The formaldehyde, by forming what is probably an addition or condensation product with the casein, forms a gel having a high degree of water-resistance. Since casein will form insoluble addition or condensation products with practically all the base metals, substantially all the base net al salts are therefore usable. The quantity of hardeher used will of course depend upon the quantity of casein and also upon the kind of hardener used.

Casein possesses a peculiar property which may be made of valuable use in a paint vehicle. The casein specified in the body or base, for the purpose of neutralizing the free alkali present in the cement may be omitted from the body in commercial manufacture if it is properly provided in the vehicle fo rming mixture. After the casein and 'ffiallslijihef'solverit"have rem acted together in what'are'prsumed to be chemically equivalent proportions, the glkali;pa e: gnate gel produced can physically adsorb an additional amount of alkalies in considerable quantity. By usifig just sufiicient Event, then, m0

r. Etta.-

ing further alkalies. Since cementitious suringredients mentioned, it will be found that at 80 faces normally contain free lime and other alleast forty percent by weight of the total paint kalies, and cement paints are most widely used should be cement and that from forty up to on such surfaces, this alkali-adsorbing or flime; ninety percent cement will give satisfactory relocking'i characteristic of a properly 'pro'p'ofsults.

'tfified caseinate vgh igle is important. Such a Where provision is made for eutralizing the 35 vehicle not only renders the paint itself efi'ecflfagalkali resentin the cemenm tively neutral, but also neutralizes excess alkao vel'ficle-forminggixtge should be used for lies present in the surface to which the paint is each 100 parts of cement. When such small perapplied. centages of vehicle-forming mixture are used no A paint constructed in accordance with the lime at all is added in the vehicle-forming m'i'i'i 90 principles of the present invention may be sucture, the free lime in the cement serving as the 1. cessfully overcoated with oil paints, either iminsolub' 1281: or e ve 1c e. or a most widely mediately after drying or years after application applicable and generally satisfactory paint, it is without danger of saponification of the oil vepreferable touseaconsiderably higher percentage hicle- Not only Oil paints but py y 1841- of vehicle-forming mixture than this, and use 95 Qpaint to thoroughly satisfactory results.

ury is the mos 'fi'tive and may be used in 0 the preservative agent. Any dry-Eowder ermicide or disinfectant which I I 11 ac na proper hardening of the cement. 1 00 to completely dissolve the casein, and by using Just sufiicient hardener to harden it, it is possible to produce a paint vehicle which will possess a considerable and valuable capacity for adsorbthat the paint will take a true cement or integral" bond to such surfaces, and not depend upon the adhesiveness of the vehicle for its bonding strength. With most of the possible in the vehicle-forming mixture just suflicient lime so that the ,adde plus the W in the cementwrly serve as the lnsolw..- b i lizer for the vehicle. In the present paint we prefer to use from ten to twenty percent of ve; very small percentag s. Borax is th r hly hicle-forming mixture and this is based on the satisfactory and has the desirable advantage of E 'fT hffifffi 'fi t being DOD-DOiSODOHS- AS has been noted above, It is preferable to use approximately the folb X y be used bOth as the Solvent and as lowing percentages, based on the total weight of the paint: Bod 70 to percent, reactionmixture: 5 to percent and vehicle-forming mixture: 5 to 20 percent.

r, more in detail, it is preferred to use the following ingredients in substantially the following proportions, all parts being by weight; Portlagdgr other hydraulic cement, parts; calcium carbona e l 0 par s; cla or kaolin, 2 to 10 parts; Ego, 2 to 10 parts; Hydrated lime, 2 to 10 parts; auminum sul hate, 2 to 10 parts; borax 1 to 5 parE and casein or a mixture of casems, 2 to 10 parts.

The materials used should, in the finished paint, preferably all be as fine as Portland cement, that is, 85% through 200 mesh. It is advantageous, however, to have the finished paint considerably finer than this, and for this reason the paint is ground to a fineness of approximately 90% through 300 mesh, as the resulting product has much smoother flow, gives better coverage and is less abrasive on spray equipment. The reacting products of course dissolve more readily when they are finely ground and mixing is therefore easier.

For rima colors the igments are ground into the paint, as ms insures unflorm dispersion of pigment matter. ,Seconda colors are made by blending primary colors m a mechanical mixer.

For application to a surface, the dry paint is placed in the mixing vessel and enough water added to produce a paste. This paste is thoroughly worked with the paddle and further water is added, with stirring, until a mixed paint of about the consistency of a slightly heavy oil paint is produced. The mixed paint may be applied with either brush or spray.

The aluminum *lghate, or alum preferably employed is the one aving the formfila A12(SO4) a lus 18H 0 but other alums, such asm alum known as potassium-aluminum sul hate, soda-alum, or ammonium-alga may be used.

1. A dry powder cement and water paint adapted to be mixed with water before using comprising a Portland cement, a mineral filler and a 150 quers and enamels and other coatings of a similar nature may be applied over the cement For the preservative agent biggloride g1 mgrgrow may e use as the preservative agent.

An important characteristic of the alkalicaseinate gel is the fact that when the casein is breaking down into its primary cleavage products the gel undergoes the process of s eresis that is: a shrinking and a giving up of tfie wat er enclosed W'filid phasefrhissyneresis is rather slow in the case of a neutral or mildly alkaline gel, even when all excess water outside the solid phase is removed, as by evaporation or otherwise. In practice when the paint has been applied to the wall and the excess water can evaporate or be taken up by the cement in its hardening, the gel will p to a hard and dry mass. Now this slow giving up of water on the part of the vehicle is of worthwhile value in a cement paint for the reason that the cement requires moisture for its proper hardening, and moreover, if the coating is to attain its maximum hardness, the cement must be kept moderately damp for several hours after the paint has been applied to the wall. The caseinate gel, in its syneresis, supplies this necessary moisture in a thoroughly satisfactory manner so that in the present paint it is quite unnecessary to employ roscopic salts to attract moisture from the a mosp ere insure Considering now the paint as a whole, the relative percentages of th thre essential parts, bodr, saatiaa-enlste s and iitk i 'i w e mixture will of course be subject to a rather wide range of choice.

The reatio- ;v entirely and a esonaly sai produced. With the re-action mixture omitted, the vehicleformir i g r n ix tnre may form from three to twenty percent ofthe total mass of the paint. With the lower percentages of vehicle-forming mixture, the higher percentages of cement in the body should be used for maximum durability. Since cement paints are most widely used on cementitious surfaces, for best results a sumcient percentage of cement should be used so COATING R PLASTIC.

quantity of calcium hydroxide and aluminum sulphate which when reacted together by the addition of water will produce not more than approximately twenty percent of hydrous aluminum oxide and not more than approximately three percent of calcium sulphate, the percentages employed being based on the quantity by weight of the cement used, the calcium sulphate acting as a retarding agent for the setting of the cement, a casein and formaldehyde which will form with the casein a product having a high degree of water resistance, sumcient casein being employed to absorb any excess lime present.

2. A dry powder cement and water paint adapted to be mixed with water before using comprising a Portland cement, a mineral filler and a quantity of calcium hydroxide and aluminum sulphate which when reacted together in the presence of water will form hydrous aluminum oxide and calcium sulphate, the percentage by weight oi. calcium hydroxide and aluminum sulphate employed to the weight of the Portland cement is such that no more than approximately three percent by weight of calcium sulphate is formed, the last-mentioned ingredient acting as a retarding agent, caseins, an alkaline solvent agent for the caseins and formaldehyde forming with the caseins a product acting as a binder having a high degree of water resistance.

WILLIAM P. D. MOROSS. 

